Ok here is the crossover part.
This was the mock up I did and asked Danny to confirm that it looked correct and he did. Thanks Danny!
Here are the parts ready to go. For details on crossover assembly read the Sticky "Crossover 101" Thread.
Edit: Make the crossover board 4 7/8 inches by 8 inches. Once you have the locations for the zip ties marked, stack them and drill both at the same time so they are the same.
Here they are ready to be hooked up.
The input wires installed with the tube connectors.
Edit: Be sure to review the tube connector Sticky thread to be sure you install them correctly.
Now I will caution others to be careful with your wire lengths as there is just enough length included in the kit. Just!
All connections made and ready to install the crossovers and woofer. Tweeter is already mounted.
You should mount the tweeter before wiring it. I drilled 1/8" holes for the tweeter wires. It fits nice and snug with no sealer needed.
Edit: Notice the Kleenex box under the crossover. That's to raise it up to make the tweeter wire shorter while soldering it to the board to save wire length.
Mounted on the bottom with 3 screws.
Edit: You can see the two screws in the front and the third is in the center of the rear coil. Drill the holes ahead of time and start the screws before inserting the crossovers in the boxes. Be sure the screws you use are not so long that they go all the way through the bottom. I used 3/4" long screws.
Adding the poly fill as per the instructions.
Edit: Picked some up at a craft store. It does not come in the kit.
And assembled and bolted to the stands. Again I will take some better photos soon.
Showing the Norez and tweeter wires.
Edit: I drilled 1/8 inch holes in each front corner for the tweeter wires. It is a tight fit and does not need sealer.
Tube connectors and Anti Cable speaker cables.
Grill mounting clips installed. All that is left is to install the grill cloth.
Edit: A tip is you use the plastic clips like I did. Place the grill frame on the speaker. Mark the location where you want the clips. I put them 1 1/2 inches from the ends. Then drill a small 1/16 inch hole all the way through the frame and into the top of the box. This will locate the larger holes for the clips perfectly. In this case the hole are 3/8" in the box and 1/4" in the grill frame. I used forstner bits. You could use brad point bits but I would not use standard drill bits.
Grill frame installed. I decided to round over the top opening of the frame.
That was not in the instructions but seemed like a good idea as you don't want sharp edges near drivers inside or out of the speakers.
A nice flair for the sound to more smoothly roll out the top.
Note also that the grill cloth and mounting clips do not come with the kit.
I purchased these from "Simply Speakers". He even has a video on how to install the cloth on your frames.
And here they are in the primary position in my room all hooked up to the Rogue Pharaoh integrated amp that they will be paired with in my dads system.
As I mentioned all that is left is to install the grill cloth and then they are complete.
This has been a fun project for me. They turned out beautiful. The pictures don't do them justice. They really look sharp in person.
I will have the grills finished and get some good photos up soon.